BATTERY CHARGERS NO. 3

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1 Date: January 10, 1992 BATTERY CHARGERS NO. 3 To: Subject: Manufacturers of Commercial/Industrial Battery Chargers Expansion of CSA Certification Service for Power Supplies to Include Low Voltage, Outdoor Usage Vehicular Battery Chargers Evaluated to the Requirements of Technical Information Letter (T.I.L.) No. Q-8 CSA is pleased to announce an expansion of its Certification Service for power supplies to include low voltage, outdoor usage vehicular battery chargers. The Certification will be based on the requirements specified in the attached T.I.L. No. Q-8. Background The technological advancements in commercial/industrial batteries and battery chargers have made it feasible for manufacturers to develop low voltage, outdoor usage vehicular battery chargers. Consequently, CSA has received inquiries from manufacturers to certify such products. Rationale CSA Standard CAN/CSA-C22.2 No M89, "Battery Chargers" contains requirements for low voltage fixed (mounting) commercial and industrial battery chargers for use indoors, but does not include specific requirements for such equipment used outdoors. At the request of industry and to recognize this construction, CSA has developed requirements documented in the attached T.I.L. No. Q-8 for low voltage, outdoor usage vehicular battery chargers. The requirements contained in T.I.L. No. Q-8 will be used in conjunction with CSA Standard CAN/CSA-C22.2 No M89, "Battery Chargers". Direction CSA is now accepting applications for certification of low voltage, outdoor usage vehicular battery chargers /JM/SIU/bds Page 1 of 8

2 CSA Can Help If you wish to make an application or require additional information regarding this Informs, please contact one of our Offices or Overseas Agencies listed below. Rexdale Office (Information) - Telephone: (416) , Telefax: (416) (Standards Sales) - Telephone: (416) , Telefax: (416) Moncton Office - Telephone: (506) , Telefax: (506) Montreal Office - Telephone: (514) , Telefax: (514) Vancouver Office - Telephone: (604) , Telefax: (604) Winnipeg Office - Telephone: (204) , Telefax: (204) Edmonton Office - Telephone: (403) , Telefax: (403) Brussels Office - Telephone: (32) , Telefax: (32) Hong Kong Office - Telephone: (852) , Telefax: (852) Taiwan Office - Telephone: (886) , Telefax: (886) BSI/CSA Agency - Telephone: (908) , Telefax: (908) JMI/CSA Agency - Telephone: (3) , Telefax: (3) KEMA/CSA Agency - Telephone: (85) , Telefax: (85) * * * * * * * * * * * /JM/SIU/bds Page 2 of 8

3 Ref No: Battery Chargers No. 3 TECHNICAL INFORMATION LETTER NO. Q-8 Certification and Testing Division Product Group: Power Supplies Date: January 10, 1992 Issued By: John Marshall SUBJECT: Requirements for Low Voltage, Outdoor Usage Vehicular Battery Chargers AFFECTED EQUIPMENT: Commercial / Industrial Battery Chargers REFERENCE PUBLICATIONS: C Safety Standard for Electrical Installations - Canadian Electrical Code Part I C22.2 No. 0-M91 - General Requirements - Canadian Electrical Code Part II C22.2 No. 0.4-Ml982 - Bonding and Grounding of Electrical Equipment C22.2 No. 94-M91 - Special Purpose Enclosures C22.2 No M91 - Commercial and Industrial Power Supplies C22.2 No M89 - Battery Chargers CAN3-C Preferred Voltage Levels for AC Systems 0 to 50,000 V INTRODUCTION CSA has been requested to Certify fixed outdoor battery chargers with low voltage dc output, for use with battery powered vehicles. CSA Standard CAN/CSA-C22.2 No M89 contains requirements for low voltage fixed (mounting) commercial and industrial battery chargers for use indoors, but does not include specific requirements for such equipment when used outdoors. In order to accommodate these requests and to recognize this construction, requirements were developed to deal with the outdoor environment, and the shock hazards associated with low voltage output circuits. This Technical Information Letter (TIL) contains construction and test requirements used to evaluate outdoor low voltage commercial / industrial vehicular battery chargers (to be used in addition to the requirements Of C22.2 No M89) Scope This TIL contains requirements for battery chargers having a low voltage dc output and intended for fixed mounting outdoors, that supplement those of C22.2 No M89. The general scope of C22.2 No M89 shall apply to the subject products, except as specifically amended by this document. This TIL contains - requirements only- for equipment having -metal enclosures. Requirements for equipment having polymeric enclosures are not included in this document. \TP42\TL911024\ Page 3 of 8

4 2.0 Construction 2.1 Enclosures An enclosure shall be provided that complies with the "Type 311 requirements contained in CSA Standard CAN/CSA- C22.2 No. 94-M91. As an alternative an enclosure shall be provided that complies with the "Type 3R" requirements contained in CSA Standard CAN/CSA-C22.2 No. 94-M91, followed by the leakage current test of clause 4.3. All products shall comply with the dielectric voltage withstand tests of clause 4.1, after the water exposure conditioning for enclosures of "Type 311, and the water exposure conditioning and leakage current test for enclosures of "Type 3R". Rationale: As the products covered by this TIL are intended for outdoor installation, enclosure(s) that are resistant to rain and snow are required The enclosure shall comply with the requirements of CSA Standard CAN/CSA-C22.2 No M91 Clause for the thickness of sheet metal enclosures for live parts. Enclosure walls having large unsupported areas in the external surface shall comply with the deflection test specified in CSA Standard CAN/CSA-C22.2 No M91, Clause 6.10, and the impact test of clause No bare live parts, considered to be a shock hazard as defined in C22.2 No M89, shall be accessible using the articulated finger probe of CSA-C22.2 No M89, Figure 1. For purposes of this test, film coated wire is considered to be a bare live part. The probe shall be inserted to any depth permitted by the construction, using an applied force of not greater than 4.4 N. The probe shall be rotated, or angled before, during and after insertion into an opening At points to which a wiring system is to be connected, uncoated steel shall be at least 0.78 mm thick and zinc coated steel at least 0.88 mm thick. 2.2 Supply Connections The equipment shall have provision for conduit connection to the supply in accordance with the requirements of CSA Standard C22.2 No. 0-M Output Circuit The battery charger output circuit shall be isolated from the primary circuit and shall be floating with respect to ground. Rationale: Vehicular battery chargers are required to have output circuits isolated from ground to reduce the risk of fire hazard resulting from contact between the vehicle and the charger enclosure or other grounded metal parts. Low voltage battery chargers are additionally required to have floating output circuits to reduce the risk of shock hazard, as the polarity of the vehicle and the isolation of the battery circuit from the vehicle chassis cannot be assured. \TP42\TL911024\ Page 4 of 8

5 2.4 Spacings The product shall meet the spacing requirements of Table 2 of C22.2 No M89. Spacings, based on live parts having the same voltage as the low voltage output circuit, shall be provided and maintained between the low voltage output circuit and grounded parts. The notes of C22.2 No M89 - Table 2 permitting spacing reduction shall not be applied to low voltage output circuits of units intended to be installed outdoors. 2.5 Low Voltage Battery Charger Output Connector(s) Battery charger low voltage output cable connectors shall be of a polarized, non-standard configuration, dead front type. The plug shall meet the performance and construction requirements of CSA Standard C22.2 No (when evaluated with the mating connector recommended by the manufacturer), and the spacing and accessibility requirements of C22.2 No M The battery charger output low voltage cable connector shall meet the requirements for Type 3R" enclosures contained in C22.2 No. 94-m9l, when separated from the mating load connector unless the plug is interlocked so that the plug contacts are not energized (by the low voltage output circuit) when disconnected from the vehicle / load The interlock referred to in Clause shall open all conductors in the low voltage output circuit or de-energize the primary circuit supplying power to the low voltage output (battery charging) circuit. Extra low voltage sensing circuits may remain energized during the output circuit interlock operation period The combination of the low voltage battery charger output cable connector and the mating receptacle recommended by the manufacturer shall comply with the bridging current test of Clause 4.5. Rationale: This requirement is intended to reduce the risk of shock hazard during connection and disconnection of the charger to / from the vehicle The output cable shall meet the pull test of clause 4.2. In-line breakaway cable connectors, if provided to facilitate disconnect during this test, shall meet the requirements of clause 2.5.1, and after separation. Rationale: This requirement is intended to prevent damage to the charger and the output cable / plug in the event that the vehicle being charged is moved without the battery charger being disconnected. 2.6 Output wiring Output cords or cables shall be of the extra hard 'usage type suitable for use in wet locations as permitted in the CEC Part I C , Table 11. \TP42\TL911024\ Page 5 of 8

6 3.0 Markings 3.1 In addition to the markings required by C22.2 No M89, the product shall be marked with the enclosure classification "Type 31, or "Type 3R" corresponding to the applicable test of clause Tests 4.1 Dielectric Voltage Withstand Tests In addition to the applicable tests contained in C22.2 No clause 6.7, a dielectric voltage withstand test shall be applied between a low voltage output circuit and grounded metal parts. The test voltage shall be 1000 V ac Plus twice the secondary circuit voltage but not less than 1500 V ac. The test voltage shall be applied for a period of one minute without breakdown In addition to the requirements of clause 6.7 (C22.2 No M89), the dielectric tests shall be performed after the rain exposure tests required by clause Output Cable Strain Relief Test The output cable strain relief test shall be applied to the low voltage output cable, including the output cable connector and the securement / connection means at the charger A pull shall be applied, simultaneously parallel to the longitudinal axis of the output cable and perpendicular to the cable entry axis into the output connector, by means of the mating connector (specified by the manufacturer) intended to be used as part of the vehicle to be charged. Rationale: This test is intended to simulate the movement of the vehicle away from the charger (without being disconnected), at a right angle to the line-of insertion of the charger plug into the vehicle receptacle No maximum pull force is specified for this test. The pull shall be applied until the circuit is broken The result of the test is acceptable if: (i) (ii) the cable is not damaged (no failure of insulation); and no live parts are exposed. \TP42\TL911024\ Page 6 of 8

7 4.3 Low Voltage Output Circuit Leakage Current Test Rationale: Leakage current measurement at the output circuit conductors is important to reduce the risk of electric shock during vehicle charging. As the vehicle construction is unknown (and may be of the traditional metal frame / skin construction), and as connection between the vehicle batteries and the frame is unknown (both in impedance and polarity), it is assumed that one of the low voltage output circuit conductors will be accessible (via the vehicle). Leakage current will become accessible through contact with the vehicle during charging General The leakage current test is performed on all products (regardless of enclosure classification) after the humidity conditioning of clause The leakage current test shall be performed after the water exposure test (without additional humidity conditioning) for enclosures evaluated to the "Type 3R" classification as required in clause Humidity Conditioning The product shall be placed in a test chamber containing air with a relative humidity of 93 ± 2 % and an ambient chamber temperature of 32 ± 2 C for a period of 48 h. The product shall not be connected to the supply during humidity conditioning, unless intended for continuously energized operation (specified by the manufacturer in the- installation and usage instructions provided with the unit) Leakage Current Measurement The output circuit leakage current test shall be performed, as outlined in clause 6.5 of C22.2 No. 0-M91. The test circuit shall be appropriate for the supply system configuration of the product, selected from Figure 2 and Table 2 of C22.2 No. 0-M91. The equipment grounding conductor shall be continuous (not opened) for this test. Rationale: The test circuits shown in C22.2 No. 0-M91 are intended to be used for the evaluation of cord connected equipment. Fox, cases in which leakage measurement is required at exposed points of permanently connected equipment, the supply circuit ground conductor is permitted to remain intact The supply voltage for this test shall be the upper limit (under normal operating conditions) for the range associated with the nominal supply voltage of the product, taken from CAN3-C Table The leakage current shall be measured from each output circuit conductor in turn, in all combinations of test circuit switch settings. \TP42\TL911024\ Page 7 of 8

8 4.3.4 Criteria of Acceptance The results of the test are acceptable if the leakage current measured does not exceed 0.5 ma, under any of the test circuit switch settings. 4.4 Enclosure Impact Where required by clause 2.1.2, the part of the enclosure being investigated shall, be subjected to a single impact of 14 J using a steel sphere of approximately 50 mm dia, having a mass of approximately 0.5 kg. The ball shall be permitted to fall freely, or be swung as a pendulum while suspended by a fine wire, through the height necessary to develop the required energy As a result of the impact test there I shall be no permanent reduction of the required spacings below the values of clause Bridging Current Test Rationale: "Bridging Current" measurement at the output circuit conductors is important to reduce the risk of electric shock during insertion of a charger connector (that has been exposed to outdoor weather conditions) into the load vehicle connector. As the vehicle construction is unknown (and may be of the traditional metal frame / skin construction), and as connection between the vehicle batteries and the frame is unknown (both in impedance and polarity), it is assumed that one side of the low voltage charger circuit will be accessible (via the vehicle) The output connector, while separated from its mating receptacle, shall be subjected to water spray conditioning as specified for type 3R enclosures in CSA Standard C22.2 No. 94. Following conditioning, the output connector shall be mated with the receptacle recommended by the manufacturer. The (bridging) current flowing through a resistor shall be measured, between a 100 mm by 200 mm water soaked wet pad (wrapped around the connector) and each of the low voltage dc output circuit conductors The bridging current shall not exceed 2.0 ma dc. \TP42\TL911024\ Page 8 of 8